Personal wear article having containment flaps

ABSTRACT

An absorbent article has an inner layer, an outer layer and an absorbent body therebetween. A pair of containment flaps is secured to the inner layer in spaced relation with each other, with each flap having a first layer extending from a base to a distal end of the flap whereby the flap first layer has a lateral surface and a medial surface. A liquid permeable second layer is disposed in generally opposed relationship with the medial surface of the flap first layer and is free from fixed engagement with at least a portion of the medial surface of the flap first layer to define a surge chamber therebetween for receiving liquid body waste. A surge member is disposed within the surge chamber for taking in liquid waste received in the surge chamber and releasing the liquid waste to the absorbent body.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a Continuation-in-Part of U.S. patentapplication Ser. No. 10/003,970, filed Oct. 31, 2001, the entire text ofwhich is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to absorbent articles, such asthose used as personal care products, and more particularly to such anabsorbent article having containment flaps for improved containment ofliquid body waste.

[0003] Absorbent articles find widespread use as personal care productssuch as diapers, children's toilet training pants, adult incontinencegarments, sanitary napkins and the like, as well as surgical bandagesand sponges. These articles absorb and contain body waste and are oftenintended to be discarded after a limited period of use; i.e., thearticles are not intended to be laundered or otherwise restored forreuse. Conventional absorbent articles comprise an absorbent bodydisposed between a liner adapted for contacting the wearer's skin and anouter cover for inhibiting liquid body waste absorbed by the absorbentbody from leaking out of the article. The liner of the absorbent articleis typically liquid permeable to permit liquid body waste to passtherethrough for absorption by the absorbent body.

[0004] Desired performance objectives of these absorbent articlesinclude little or no leakage from the article and a dry feel to thewearer. However, some available absorbent articles may fail to inhibitleakage, even where the total absorbent capacity of the absorbent bodyis unrealized. Leakage can result from an insufficient rate of liquidbody waste passing through the liner of the article or from aninsufficient rate of absorption by the absorbent body, especially uponthe occurrence of a second or even third surge of liquid body waste. Forexample, in diapers and children's training pants, a surge of urineflowing laterally outward toward opposite edges of the article may notpenetrate through the liner of the article or be absorbed by theabsorbent body at a rate sufficient to prevent some of the urine fromleaking out between the wearer's skin and the opposite edges of thearticle.

[0005] One attempt to eliminate such leakage is the provision of a pairof longitudinally extending (e.g., front-to-back) containment flaps onthe liner of the article. The containment flaps are typically spacedlaterally from each other and positioned inward from the opposite edgesof the article, particularly in the crotch area of diapers and trainingpants. For example, U.S. Pat. No. 5,895,382 discloses containment flapsfor training pants in which the flaps each include a liquid permeableouter layer and a liquid impermeable inner layer. Elastic members areheld between the outer and inner layers at the distal end of each flapto bias the flaps toward a generally upright position away from theliner of the article. The outer layer of the flap is folded over a smallportion of the inner layer at the distal end of the flap to enclose theelastic members within the flap.

[0006] These containment flaps are intended to provide a barrier againstthe laterally outward flow of liquid body waste toward the edges of thearticle. In practice, however, leakage may still occur if a surge ofliquid waste is released by the wearer because the absorbent article maynot absorb the liquid at a rate sufficient to avoid substantial outwardflow against the flaps, which may result in flow over the containmentflaps and subsequent leakage from the edges of the article.

[0007] Therefore, despite the improved body waste containment obtainedby providing conventional containment flaps, there continues to be aneed for further improvements to inhibit leakage from absorbent articlesresulting from surges of liquid body waste rushing laterally outwardover the containment flaps.

SUMMARY OF THE INVENTION

[0008] In one embodiment, an absorbent article of the present inventiongenerally comprises an inner layer adapted for contiguous relationshipwith the wearer wherein at least a portion of the inner layer is liquidpermeable. An outer layer is in opposed relationship with the innerlayer and an absorbent body is disposed between the inner layer and theouter layer of the article for absorbing liquid body waste. A pair ofcontainment flaps is secured to the inner layer of the article in spacedrelation with each other. Each flap has a base secured to the innerlayer of the article and a distal end. At least a portion of the distalend is movable relative to the base to a position in which the distalend is spaced from the inner layer of the article. Each containment flapgenerally comprises a first layer extending from the base of the flap tothe distal end of the flap wherein the flap first layer has a lateralsurface and a medial surface. A liquid permeable second layer isdisposed in generally opposed relationship with the medial surface ofthe flap first layer and is free from fixed engagement with at least aportion of the medial surface of the flap first layer to define a surgechamber therebetween for receiving liquid body waste. A surge member isdisposed within the surge chamber for taking in liquid waste received inthe surge chamber and releasing the liquid waste to the absorbent body.

[0009] In another embodiment, an absorbent article of the presentinvention generally comprises an inner layer adapted for contiguousrelationship with the wearer wherein at least a portion of the innerlayer is liquid permeable. An outer layer is in opposed relationshipwith the inner layer of the article and an absorbent body is disposedbetween the inner layer and the outer layer of the article for absorbingliquid body waste. A pair of containment flaps is secured to the innerlayer of the article in spaced relation with each other, with each flaphaving a base secured to the inner layer of the article and a distalend. At least a portion of the distal end is movable relative to thebase to a position in which the flap is spaced from the inner layer ofthe article. The containment flaps each comprise a first layer extendingfrom the base of the flap to the distal end of the flap wherein the flapfirst layer has a lateral surface and a medial surface. A liquidpermeable second layer at least partially surrounds the lateral andmedial surfaces of the flap first layer. The flap second layer is freefrom fixed engagement with at least a portion of the medial surface ofthe flap first layer to define a surge chamber therebetween forreceiving liquid body waste. A flow control member is disposed in thesurge chamber for controlling the flow of liquid body waste received inthe surge chamber.

[0010] In yet another embodiment, an absorbent article of the presentinvention generally comprises an inner layer adapted for contiguousrelationship with the wearer wherein at least a portion of the innerlayer is liquid permeable. An outer layer is in opposed relationshipwith the inner layer of the article and an absorbent body is disposedbetween the inner layer and the outer layer of the article for absorbingliquid body waste. A pair of containment flaps is secured to the innerlayer of the article in spaced relation with each other, with each flaphaving a base secured to the inner layer of the article and a distalend. At least a portion of the distal end is movable relative to thebase to a position in which the flap is spaced from the inner layer ofthe article. The containment flaps each comprise a first layer extendingfrom the base of the flap to the distal end of the flap, wherein theflap first layer has a lateral surface and a medial surface. A liquidpermeable second layer is in opposed relation with the medial surface ofthe flap first layer. The flap second layer is free from fixedengagement with at least a portion of the medial surface of the flapfirst layer to define a surge chamber therebetween for receiving liquidbody waste. The liquid permeable portion of the inner layer of thearticle is interposed between the surge chamber and the absorbent bodyof the article. A flow control member is disposed within the surgechamber for controlling the flow of liquid body waste received in thesurge chamber.

[0011] In general an personal wear article according to one embodimentof the present invention comprises a substrate adapted for contiguousrelationship with the wearer of the article, and a pair of containmentflaps secured to the substrate for contiguous relationship with thewearer of the article. The containment flaps are in spaced relation witheach other, with each flap having a base secured to the substrate and adistal end, at least a portion of which is movable relative to the baseto a position in which the distal end is spaced from the substrate ofthe article. The containment flaps each comprise a first layer extendingfrom the base of the flap to the distal end of the flap, wherein theflap first layer has a lateral surface and a medial surface. A liquidpermeable second layer is disposed in generally opposed relationshipwith the medial surface of the flap first layer and is free from fixedengagement with at least a portion of the medial surface of the flapfirst layer to define a surge chamber therebetween for receiving liquidbody waste. A surge member is disposed within the surge chamber fortaking in liquid waste received in the surge chamber and subsequentlyreleasing the liquid waste for transfer out of the surge chamber.

[0012] Other aspects and features of this invention will be in partapparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a perspective of a children's toilet training pantsincorporating containment flaps;

[0014]FIG. 2 is a top plan view of the training pants of FIG. 1 with thepants shown unfastened and unfolded;

[0015]FIG. 3 is a fragmentary front elevation of training pantspartially fitted on a child;

[0016]FIG. 4 is a separated cross-section of the training pants of FIG.1 taken laterally through an anterior region of the pants;

[0017]FIG. 5 is a separated cross-section similar to that of FIG. 4showing a second embodiment of the containment flaps;

[0018]FIG. 6 is a separated cross-section similar to that of FIG. 4showing a third embodiment of the containment flaps;

[0019]FIG. 7 is a separated cross-section similar to that of FIG. 6 withan alternative flow control member disposed within each containmentflap;

[0020]FIG. 8 is a separated cross-section similar to that of FIG. 5showing a fourth embodiment of the containment flaps; and

[0021]FIG. 9 is a separated cross-section similar to that of FIG. 8 withan alternative flow control member disposed within each containmentflap.

[0022] Corresponding reference characters indicate corresponding partsthroughout the drawings.

[0023] Definitions

[0024] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings:

[0025] (a) “Bonded” refers to the joining, adhering, connecting,attaching, or the like, of two elements. Two elements will be consideredto be bonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

[0026] (b) “Film” refers to a thermoplastic film made using a filmextrusion and/or foaming process, such as a cast film or blown filmextrusion process. The term includes apertured films, slit films, andother porous films which constitute liquid transfer films, as well asfilms which do not transfer liquid.

[0027] (c) “Hydrophilic” describes fibers or the surfaces of fiberswhich are wetted by the aqueous liquids in contact with the fibers. Thedegree of wetting of the materials can, in turn, be described in termsof the contact angles and the surface tensions of the liquids andmaterials involved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90 aredesignated “nonwettable” or hydrophobic.

[0028] (d) “Layer” when used in the singular can have the dual meaningof a single element or a plurality of elements.

[0029] (e) “Liquid impermeable,” when used in describing a layer ormulti-layer laminate means that liquid body waste, such as urine, willnot pass through the layer or laminate, under ordinary use conditions,in a direction generally perpendicular to the plane of the layer orlaminate at the point of liquid contact. Liquid body waste may spread orbe transported parallel to the plane of the liquid impermeable layer orlaminate, but this is not considered to be within the meaning of “liquidimpermeable” when used herein.

[0030] (f) “Liquid permeable” refers to any material present in one ormore layers which is not liquid impermeable.

[0031] (g) “Meltblown” refers to fibers formed by extruding a moltenthermoplastic material through a plurality of fine, usually circular,die capillaries as molten threads or filaments into converging highvelocity heated gas (e.g., air) streams which attenuate the filaments ofmolten thermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface toform a web of randomly dispersed meltblown fibers. Such a process isdisclosed for example, in U.S. Pat. No. 3,849,241 to Butin et al.Meltblown fibers are microfibers which may be continuous ordiscontinuous, are generally smaller than about 0.6 denier, and aregenerally self bonding when deposited onto a collecting surface.Meltblown fibers used in the present invention are preferablysubstantially continuous in length.

[0032] (h) Non-woven” and “non-woven web” refer to materials and webs ofmaterial which are formed without the aid of a textile weaving orknitting process.

[0033] (i) “Pliable” refers to materials which are compliant and whichwill readily conform to the general shape and contours of the wearer'sbody.

[0034] (j) “Spunbond” refers to small diameter fibers which are formedby extruding molten thermoplastic material as filaments from a pluralityof fine capillaries of a spinnerette having a circular or otherconfiguration, with the diameter of the extruded filaments then beingrapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appelet al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No.3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 toKinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 toPeterson, and U.S. Pat. No. 3,542,615 to Dobo et al., each of which isincorporated herein in its entirety by reference. Spunbond fibers aregenerally continuous and often have average deniers larger than about0.3, more particularly, between about 0.6 and about 10.

[0035] (k) “Superabsorbent” refers to a water-swellable, water-insolubleorganic or inorganic material capable, under the most favorableconditions, of absorbing at least about 15 times its weight and, moredesirably, at least about 30 times its weight in an aqueous solutioncontaining 0.9 weight percent sodium chloride. The superabsorbentmaterials can be natural, synthetic and modified natural polymers andmaterials. In addition, the superabsorbent materials can be inorganicmaterials, such as silica gels, or organic compounds such ascross-linked polymers.

[0036] (l) “Surface” includes any layer, film, woven, nonwoven,laminate, composite, or the like, whether pervious or impervious to air,gas, and/or liquids.

[0037] (m) “Surge Layer” or “surge member” refers to a layer or membertypically comprised of nonwoven materials that can absorb a large streamor gush of liquid and release it slowly into another layer or layers.

[0038] (n) “Thermoplastic” describes a material that softens whenexposed to heat and which substantially returns to a non-softenedcondition when cooled to room temperature.

[0039] (o) “Three dimensional” refers to a garment similar to underwear,shorts or pants in that it has continuous leg and waist openings thatare bounded by material of which the garment is made. The garment may ormay not have manually tearable or refastenable seams.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] Referring now to the drawings and in particular to FIG. 1, anabsorbent article in the form of children's toilet training pants isindicated in its entirety by the reference numeral 21 and incorporatescontainment flaps, generally indicated at 23, of the present inventionfor inhibiting leakage of liquid body waste, such as urine, from thetraining pants. The absorbent article is suitable for placement againstor in proximity to the body of the wearer to absorb and/or retainvarious liquid waste discharged from the body. The absorbent article mayor may not be disposable, which refers to articles that are intended tobe discarded after a limited period of use instead of being laundered orotherwise restored for reuse. While the containment flaps 23 of thepresent invention are shown and described herein in connection withchildren's toilet training pants, it is understood that the containmentflaps may be incorporated into various other absorbent articles, such asdiapers, adult incontinence garments, sanitary napkins and the like,surgical bandages and sponges, and in other articles in which thecontaiment flaps are secured to a substrate for contiguous relationshipwith a wearer of the article, without departing from the scope of thepresent invention.

[0041] By way of illustration only, various materials and methods forconstructing the training pants 21 are disclosed in PCT PatentApplication WO 00/37009 published Jun. 29, 2000 by A. Fletcher et al;U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.; andU.S. Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., whichare incorporated herein by reference.

[0042] The training pants 21 of the illustrated embodiment generallycomprise a central absorbent assembly 25 extending longitudinally froman anterior side 27 of the training pants through a crotch region 29 toa posterior side 30 of the training pants. As seen best in FIG. 2, thecentral absorbent assembly 25 is generally rectangular, and moreparticularly it is slightly hourglass-shaped, and has laterally, ortransversely opposite side edges 32 and longitudinally opposite frontand rear waist edges respectively designated 34 and 36. Front and rearside panels 31, 38 are secured to the central absorbent assembly 25 aswill be described later herein and extend laterally outward therefromrespectively at the anterior and posterior sides 27, 30 of the trainingpants 21. To form the three-dimensional training pants 21, adjacentfront and rear side panels 31, 38 (e.g., one extending from the anteriorside 27 and one extending from the posterior side 30 on the same rightor left side of the pants) are refastenably secured together, usingfastening assemblies 40, along generally vertical seams 33 (FIG. 3). Itis understood that the front and rear side panels 31, 38 may instead bepermanently secured together, such as by ultrasonic bonding. Securingthe side panels 31, 38 together defines a central waist opening 35 and apair of leg openings 37 of the training pants 21.

[0043] With reference to FIG. 3, the training pants 21 are worn byinserting the wearer's feet through the waist opening 35 and therespective leg openings 37; grasping the training pants near the waistopening; and then pulling the pants up along the wearer's legs until thecrotch region 29 of the training pants fits snugly against the crotch ofthe wearer. The training pants 21 are illustrated in FIG. 3 as beingonly partially fitted on the child (i.e., the training pants are pulledless than fully up to the crotch) to better illustrate the containmentflaps 23 of the present invention, it being understood that the flapswill actually bend or fold along their length when the pants are pulledfully up to the crotch of the wearer. An inner layer, generallyindicated at 39, of the training pant 21 faces the skin of the wearerand is adapted for contiguity (e.g., contact or closely spaced relation)with the wearer's skin upon fitting of the training pants on the wearer.The training pants 21 also have an outer layer, generally indicated at41, facing away from the wearer's skin.

[0044] Now referring to FIG. 4, the central absorbent assembly 25 of thetraining pants 21 comprises an outer cover, generally indicated at 43, abodyside liner 45 and an absorbent body 47 disposed between the outercover and the liner. The outer cover 43 can be elastic, stretchable ornon-stretchable and is desirably a multi-layered laminate structure ofwhich at least one of the layers is liquid impermeable. For example, theouter cover 43 of the illustrated embodiment is of two-layerconstruction, including an outer layer 49 constructed of a liquidpermeable material and an inner layer 51 constructed of a liquidimpermeable material joined together by a laminate adhesive 53. Suitablelaminate adhesives, which can be applied continuously or intermittentlyas beads, a spray, parallel swirls, or the like, can be obtained fromFindley Adhesives, Inc., of Wauwatosa, Wis., U.S.A., or from NationalStarch and Chemical Company, Bridgewater, N.J., U.S.A. It is understoodthat the outer cover 43 may alternatively be constructed of a singlelayer of liquid impermeable material without departing from the scope ofthis invention.

[0045] The liquid permeable outer layer 49 of the outer cover 43 can beany suitable material and is desirably one that provides a generallycloth-like texture. One example of such a material is a 20 gsm (gramsper square meter) spunbond polypropylene nonwoven web. The outer layer49 may also be made of those materials from which the bodyside liner 45is constructed as discussed later herein. Also, while it is not anecessity for the outer layer 49 to be liquid permeable, it is desiredthat it provide a relatively cloth-like texture to the wearer.

[0046] The inner layer 51 of the outer cover 43 can be both liquid andvapor impermeable, or it can be liquid impermeable and vapor permeable.The inner layer 51 is desirably manufactured from a thin plastic film,although other flexible liquid impermeable materials may also be used.The liquid impermeable inner layer 51 (or the liquid impermeable outercover 43 when the outer cover is constructed of a single layer) inhibitswaste material against wetting articles, such as bed sheets andclothing, as well as the wearer and care giver. A suitable liquidimpermeable film for such use is a 0.02 millimeter thick polyethylenefilm commercially available from Huntsman Packaging of Newport News,Va., U.S.A.

[0047] Where the outer cover 43 is constructed of a single layer ofmaterial, it can be embossed and/or matte finished to provide a morecloth-like appearance. As earlier mentioned, the liquid impermeablematerial can permit vapors to escape from the interior of the disposableabsorbent article, while still preventing liquids from passing throughthe outer cover 43. A suitable “breathable” material is composed of amicroporous polymer film or a nonwoven fabric that has been coated orotherwise treated to impart a desired level of liquid impermeability. Asuitable microporous film is a PMP-1 film material commerciallyavailable from Mitsui Toatsu Chemicals, Inc., Tokyo, Japan, or anXKO-8044 polyolefin film commercially available from 3M Company,Minneapolis, Minn.

[0048] Leg elastic members 55 are secured between the outer and innerlayers 49, 51 of the outer cover 43, such as by being bondedtherebetween by the laminate adhesive 53, generally adjacent laterallyouter edges 56 of the inner layer of the outer cover. However, the legelastic members 55 may instead be disposed between the outer cover 43and the bodyside liner 45 and remain within the scope of this invention.In such a design, the leg elastic members can be bonded to the outercover 43 and/or the bodyside liner 45.

[0049] A wide variety of elastic materials may be used for the legelastic members 55. As is well known to those skilled in the art,suitable elastic materials include sheets, strands or ribbons of naturalrubber, synthetic rubber, or thermoplastic elastomeric polymers. Theelastic materials can be stretched and adhered to a substrate, adheredto a gathered substrate, or adhered to a substrate and then elasticizedor shrunk, for example with the application of heat, such that elasticretractive forces are imparted to the substrate. For example, onesuitable elastic material is a dry-spun coalesced multifilament spandexelastomeric thread sold under the trade name LYCRA® and available fromE.I. DuPont de Nemours and Company, Wilmington, Del., U.S.A.

[0050] The absorbent body 47 of the illustrated embodiment is somewhatrectangular and is desirably constructed to be generally compressible,pliable, non-irritating to the wearer's skin and capable of absorbingand retaining liquid body waste, such as urine. The absorbent body 47can be manufactured in a wide variety of sizes and shapes, and from avariety of liquid absorbent materials commonly used in the art. Forexample, the absorbent body 47 can suitably include a matrix ofhydrophilic fibers, such as a web of cellulosic fluff, mixed withparticles of a high-absorbency material commonly known as superabsorbentmaterial. More particularly, the absorbent body 47 of the illustratedembodiment includes a matrix of cellulosic fluff, such as wood pulpfluff, and superabsorbent hydrogel-forming particles. One suitable typeof wood pulp fluff is identified with the trade designation CR1654,available from U.S. Alliance, Childersburg, Ala., U.S.A., and is ableached, highly absorbent sulfate wood pulp containing primarily softwood fibers. However, the wood pulp fluff can be exchanged withsynthetic, polymeric, meltblown fibers or with a combination ofmeltblown fibers and natural fibers.

[0051] The superabsorbent particles can be substantially homogeneouslymixed with the hydrophilic fibers or can be non-uniformly mixed. Thefluff and superabsorbent particles can also be selectively placed intodesired zones of the absorbent body 47 to better contain and absorbliquid body waste. The concentration of the superabsorbent particles canalso vary through the thickness of the absorbent body 47. Alternatively,the absorbent body 47 can include a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area. Suitable superabsorbentmaterials can be selected from natural, synthetic, and modified naturalpolymers and materials. The superabsorbent materials can be inorganicmaterials, such as silica gels, or organic compounds, such ascross-linked polymers. Suitable superabsorbent materials are availablefrom various commercial vendors, such as Dow Chemical Company located inMidland, Mich., U.S.A., and Stockhausen GmbH & Co. KG, D-47805 Krefeld,Federal Republic of Germany.

[0052] As a general rule, the superabsorbent material is present in theabsorbent body 47 in an amount of from about 0 to about 90 weightpercent based on total weight of the absorbent body. The absorbent body47 suitably has a density within the range of about 0.10 to about 0.35grams per cubic centimeter. The absorbent body 47 may or may not bewrapped or encompassed by a suitable wrapping (not shown) that maintainsthe integrity and/or shape of the absorbent assembly. As shown in FIG.4, the absorbent body 47 overlays the inner layer 51 of the outer cover43, extending laterally between the leg elastic members 55, and issecured to the inner layer 51 of the outer cover 43, such as by beingbonded thereto with adhesive 57.

[0053] Still referring to FIG. 4, the bodyside liner 45 overlays theabsorbent body 47 to isolate the wearer's skin from liquid body wasteretained by the absorbent body and is secured to at least a portion ofthe absorbent body, such as by being bonded thereto using a suitableadhesive 59. The liner 45 further extends beyond the absorbent body 47to overlay a portion of the inner layer 51 of the outer cover 43,particularly in the crotch region 29 of the pants 21, and is securedthereto, such as by being bonded thereto by the adhesive 57, tosubstantially enclose the absorbent body between the outer cover and theliner about the periphery of the absorbent body. While the bodysideliner 45 shown in FIG. 4 is dimensioned slightly smaller than the outercover 43, it is understood that the liner and outer cover may be of thesame dimensions, or the liner may be sized larger than the outer cover,without departing from the scope of this invention. The bodyside liner45 is desirably compliant, soft feeling, and non-irritating to thewearer's skin and can be less hydrophilic than the absorbent body 47 topresent a relatively dry surface to the wearer and permit liquid bodywaste to readily penetrate through its thickness.

[0054] The bodyside liner 45 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the bodyside liner 45. For example,the bodyside liner 45 can be composed of a meltblown or spunbonded webof polyolefin fibers. The bodyside liner 45 can also be a bonded-cardedweb composed of natural and/or synthetic fibers. The bodyside liner 45can be composed of a substantially hydrophobic material, and thehydrophobic material can, optionally, be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity. For example, the material can be surface treated withabout 0.28 weight percent of a surfactant commercially available fromthe Rohm and Haas Co. under the trade designation Triton X-102. Thesurfactant can be applied by any conventional means, such as spraying,printing, brush coating or the like. The surfactant can be applied tothe entire bodyside liner 45 or can be selectively applied to particularsections of the liner.

[0055] A suitable liquid permeable bodyside liner 45 is a nonwovenbicomponent web having a basis weight of about 27 gsm. The nonwovenbicomponent can be a spunbond bicomponent web, or a bonded cardedbicomponent web. Suitable bicomponent staple fibers include apolyethylene/polypropylene bicomponent fiber available from CHISSOCorporation, Osaka, Japan. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Other fiber orientations are possible, such as multi-lobe,side-by-side, end-to-end, or the like. While the outer cover 43 andbodyside liner 45 of the central absorbent assembly 25 can includeelastomeric materials, it is contemplated that the central absorbentassembly may instead be generally inelastic, wherein the outer cover,the bodyside liner and the absorbent body 47 include materials that aregenerally non-elastomeric.

[0056] A surge layer 61, similar to that disclosed in U.S. Pat. No.5,562,650, the entire disclosure of which is incorporated herein byreference, lies between the bodyside liner 45 and the absorbent body 47for quickly absorbing surges of liquid body waste that penetrate theliner, and then slowly releasing the liquid body waste to the absorbentbody. One suitable material from which the surge layer 61 can beconstructed has a basis weight of about 50 gsm, and includes athrough-air-bonded-carded web of a homogenous blend of 60 percent 3denier bicomponent fiber including a polyester core/polyethylene sheath,commercially available from BASF Corporation, and 40 percent 6 denierpolyester fiber, commercially available from Hoechst CelaneseCorporation of Portsmouth, Va., U.S.A. The surge layer 61 of theillustrated embodiment is secured to the absorbent body 47, such as bybeing bonded thereto using the adhesive 59 that secures the liner 45 tothe absorbent body. The liner 45 is further secured to the surge layer61, such as by being bonded thereto using a suitable adhesive 63. It isunderstood, however, that the surge layer 61 may be omitted altogether,so that the liner 45 lies directly on the absorbent body 47 along thefull lateral extent thereof, without departing from the scope of thisinvention.

[0057] The front and rear side panels 31, 38 of the absorbent article 21can be permanently bonded to the central absorbent assembly 25 of thetraining pants 21 at the respective anterior and posterior sides 27, 30thereof. For example, as shown in FIG. 4, the front side panels 31 ofthe illustrated embodiment are secured to the inner layer 51 of theouter cover 43, such as by being bonded thereto by adhesive 65, or bythermal, ultrasonic or pressure bonding, and are also secured to theouter layer 49 of the outer cover, such as by being bonded thereto byadditional adhesive 66, or by thermal, ultrasonic or pressure bonding,to extend transversely beyond the transverse edges 32 of the centralabsorbent assembly 25 at the anterior side 27 of the training pants 21as shown in FIG. 2. The rear side panels 38 are secured to the innerlayer 51 and outer cover 43 at the posterior side 30 of the trainingpants 21 in a similar manner. Alternatively, the side panels 31, 38 canbe formed integrally with the central absorbent assembly 25, such as bybeing formed integrally with the outer cover 43 or the bodyside liner45.

[0058] For improved fit and appearance, the side panels 31, 38 desirablyhave an average length dimension measured parallel to the longitudinalaxis of the training pants 21 that is about 20 percent or greater, andparticularly about 25 percent or greater, of the overall lengthdimension of the training pants, also measured parallel to thelongitudinal axis. For example, for training pants 21 having an overalllength dimension of about 54 centimeters, the side panels 31, 38desirably have an average length dimension of about 10 centimeters orgreater, such as about 15 centimeters.

[0059] Each of the side panels 31, 38 can be constructed of one or moreindividual, distinct pieces of material. For example, each side panel31, 38 can include first and second side panel portions (not shown)joined at a seam (not shown), with at least one of the portionsincluding an elastomeric material. Alternatively, each individual sidepanel 31, 38 can be constructed of a single piece of material foldedover upon itself along an intermediate fold line (not shown).

[0060] The side panels 31, 38 desirably include an elastic materialcapable of stretching transversely (e.g., laterally outward) of thetraining pants 21. Suitable elastic materials, as well as one describedprocess of incorporating elastic side panels into training pants, aredescribed in the following U.S. Pat. No. 4,940,464 issued Jul. 10, 1990to Van Gompel et al.; U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 toPohjola; U.S. Pat. No. 5,104,116 issued Apr. 14, 1992 to Pohjola; andU.S. Pat. No. 5,046,272 issued Sep. 10, 1991 to Vogt et al.; all ofwhich are incorporated herein by reference. As an example, suitableelastic materials include a stretch-thermal laminate (STL), aneck-bonded laminated (NBL), a reversibly necked laminate, or astretch-bonded laminate (SBL) material. Methods of making such materialsare well known to those skilled in the art and described in U.S. Pat.No. 4,663,220 issued May 5, 1987 to Wisneski et al.; U.S. Pat. No.5,226,992 issued Jul. 13, 1993 to Morman; and European PatentApplication No. EP 0 217 032 published on Apr. 8, 1987 in the names ofTaylor et al.; all of which are incorporated herein by reference.Alternatively, the side panels 31, 38 may include other woven ornonwoven materials, such as those described above as being suitable forthe outer cover 43 or bodyside liner 45, or stretchable but inelasticmaterials.

[0061] In the illustrated embodiment, the inner layer 39 of the trainingpants 21 is primarily defined by the liner 45, particularly in thecrotch region 29 of the pants. As used herein, the inner layer 39 of thetraining pants 21 generally refers to that layer of the pants facing thewearer's skin and adapted for contiguity therewith when the trainingpants are fitted on the wearer's body. It is contemplated that the innerlayer 39 of the training pants 21 may be further defined by elements inaddition to the liner 45. For example, at the anterior and posteriorsides 27, 30 of the training pants 21, the side panels 31, 38 extendlaterally outward beyond the liner 45 and contact the wearer's skin,thereby together with the liner 45 defining the inner layer 39 of thetraining pants. Through the crotch region 29 of the training pants 21,the outer cover 43 extends laterally outward beyond the liner 45, andthe side panels 31 do not extend longitudinally through the crotchregion, so that the outer cover contacts the wearer's skin, therebytogether with the liner defining the inner layer 39. It is alsounderstood that elements other than the side panels 31, 38 or outercover 43 may overlay, underlie or otherwise extend laterally beyond theliner 45 to face the wearer's skin in contiguity therewith at leastpartially to define the inner layer 39 of the training pants 21 withoutdeparting from the scope of this invention.

[0062] The outer layer 41 of the training pants 21 of the illustratedembodiment, facing away from the wearer's skin, is broadly defined bythe outer layer 49 of the outer cover 43. It is contemplated, however,that the training pants outer layer 41 may be defined by elements (notshown) other than or in addition to the outer layer 49 of the outercover 43 without departing from the scope of this invention.

[0063] The containment flaps 23 of the present invention are secured tothe inner layer 39 (in the illustrated embodiment, the bodyside liner45) in generally parallel, spaced relation with each other laterallyinward of the leg openings 37 and extend longitudinally from theanterior side 27 of the training pants, through the crotch region 29 tothe posterior side 30 of the training pants 21. Each containment flap 23comprises a first, inner layer 67 having medial (e.g., generally inwardfacing) and lateral (e.g., generally outward facing) surfaces,respectively designated 69 and 71. The flap inner layer 67 is desirablyconstructed of a liquid impermeable material, but may instead beconstructed of a liquid permeable material. A portion of the medialsurface 69 of the flap inner layer 67 extends in opposed relation withthe bodyside liner 45 and is secured thereto, such as by being bondedthereto by suitable adhesive 73, to broadly define a base, generallyindicated at 74, of the flap 23. The base 74 of the flap 23 shown inFIG. 4 extends laterally beyond the liner 45 and is further secured tothe side panels 31, 38 at the anterior and posterior sides 27, 30 of thetraining pants 21, such as by bonding the medial surface 69 of the flapinner layer 67 to the side panels by suitable adhesive 75. While notshown in the drawings, the flap inner layer 67 may be further secured tothe inner layer 51 of the outer cover 43 through the crotch region 29 ofthe training pants 21 to inhibit liquid body waste against flowing outof the training pants between the flap 23 and the outer cover 43.However, it is understood that the flap 23 may be secured only to thebodyside liner 45, or only to the outer cover 43, and remain within thescope of this invention.

[0064] The lateral spacing between the respective bases 74 of thecontainment flaps 23 defines a medial region 77 of the liner 45extending laterally therebetween, and more particularly between theinnermost locations at which the bases are secured to the liner, such asalong adhesives 73 securing the inner layers 67 of the flaps to theliner. In the illustrated embodiment the bases 74 of the flaps 23 aresecured to the liner 45 generally adjacent the periphery of theabsorbent body 47. However, it is understood that the bases 74 of theflaps 23 may be secured to the liner 45 in more closely or more distallyspaced relation with each other without departing from the scope of thisinvention, as long as the bases of the flaps are secured to the linergenerally laterally inward of the securement of the liner to the outercover 43. The flap inner layer 67 further extends from the base 74 to adistal end, generally indicated at 79, of the flap 23. The distal end 79or other surfaces of the flap 23 can be secured to the liner 45 or toanother component of the pants 21 at longitudinal ends 80 (FIG. 2) ofthe flaps 23. Intermediate the longitudinal ends 80 of each flaps 23,the distal end 79 of the flap 23 is free of fixed engagement with thebase 74 of the flap and the liner 45 so that the distal end of the flapis movable relative to the base 74 of the flap and the liner 45 along atleast a portion of the flap between the longitudinal ends of the flap.

[0065] Each flap 23 further comprises a second, outer layer 81constructed of a generally liquid permeable material. The flap outerlayer 81 overlays substantially the entire lateral surface 71 of theflap inner layer 67 in closely spaced relation therewith and is securedthereto, such as by being bonded thereto by suitable adhesive 83. Anelastic member, generally indicated at 85, is secured between the flapouter layer 81 and the lateral surface 71 of the flap inner layer 67adjacent the distal end 79 of the flap 23. The elastic member 85 of theillustrated embodiment comprises three individual strands 87 ofelastomeric material extending longitudinally along the distal end 79 ofthe flap 23 in generally parallel, spaced relation with each other. Onesuitable elastic strand 87 is constructed of a LYCRA® T151 940 decitexelastic which can be obtained from E. I. du Pont de Nemours Co. ofWilmington, Del., U.S.A.

[0066] The elastic strands 87 are secured between the flap outer layer81 and the lateral surface 71 of the flap inner layer 67, such as bybeing bonded therebetween by suitable adhesive 89, in an elasticallycontractible condition such that contraction of the strands gathers andshortens the distal end 79 of the containment flap 23. As a result, uponfolding of the pants 21 to form the three dimensional article, theelastic strands 87 bias the distal end 79 of each flap 23 toward aposition spaced from the base 74 of the flap so that in the crotchregion 29 of the training pants 21, the flap extends inward from theliner 45 in a generally upright orientation as shown in FIGS. 3 and 4.It is understood that the elastic member 85 may be disposed between theflap outer layer 81 and the flap inner layer 67 other than at the distalend 79 of the flap 23 without departing from the scope of thisinvention, as long as the elastic member is spaced from the base 74 ofthe flap. It is also understood that the elastic member 85 may beomitted and the flap may instead be biased toward an upright orientationby elastic materials present in the flap inner and/or outer layers 67,81. The elastic strands 87 may extend the full length of the flap 23 orthey may extend only through a portion of the flap where the flap isdesired to be spaced from the liner 45.

[0067] Still referring to FIG. 4, the outer layer 81 of each containmentflap 23 folds over the flap inner layer 69 at the distal end 79 of theflap and extends in opposed relation with the medial surface 69 of theflap inner layer from the distal end 79 of the flap to the medial region77 of the liner 45. The flap outer layer 81 of the illustratedembodiment is secured to the medial surface 69 of the flap inner layer67, such as by being bonded thereto by suitable adhesive 91, generallyat the distal end 79 of the flap 23 to broadly define a seam 92 of theflap outer layer to the medial surface of the flap inner layer. However,it is understood that the flap outer layer 81 need not be secured to themedial surface 69 of the flap inner layer 67, so that the adhesive 91and seam 92 are omitted, and remain within the scope of this invention.

[0068] The flap outer layer 81 is further secured to the medial region77 of the liner 45, such as by being bonded thereto using a suitableadhesive 93, in laterally spaced relation with the base 74 of the flap23. In the upright orientation of the flap 23, the flap outer layer 81is generally taut as it extends between the liner 45 and the seam 92such that the flap outer layer, the portion of the liner betweenadhesive 73 and the adhesive 93, and the medial surface 69 of the flapinner layer 67 together define a generally triangular, fully enclosedsurge chamber 95 for receiving liquid body waste.

[0069] In the illustrated embodiment of FIG. 4, the width of the flapouter layer 81 extending between the liner 45 and the seam 92 (or thedistal end 79 of the flap 23 if adhesive 91 is omitted) is less than thewidth of the flap inner layer 67 extending outward from the base 74 ofthe flap 23 to the seam 92 (or distal end 79) so the flap inner layer isangled transversely and laterally inward relative to the base and theliner 45. It is contemplated that the width of the flap outer layer 81extending between the liner 45 and the seam 92 may instead be greaterthan the width of the flap inner layer 67 extending outward from thebase 74 to the seam 92 so the flap inner layer extends generallyperpendicular to the base, as long as the flap outer layer is spacedfrom the flap inner layer to form the surge chamber 95. It is alsounderstood that the flap outer layer 81 may be secured to the medialsurface 69 of the flap inner layer 67 other than at the distal end 79 ofthe flap 23, such as anywhere spaced from the base 74 of the flap, orthe flap outer layer may not be secured at all to the flap inner layer,without departing from the scope of this invention. As describedpreviously, the surge chamber 95 is partially defined by the portion ofthe medial region 77 of the liner 45 extending laterally between theadhesive 73 securing the base 74 of the flap 23 to the liner and theadhesive 93 securing the flap outer layer 81 to the liner so that theliner is interposed between the surge chamber and the absorbent body 47of the training pants 21.

[0070] The surge chamber 95 extends longitudinally substantially thelength of the flap 23 from the anterior side 27 through the crotchregion 29 to the posterior side 30 to permit liquid body waste receivedin the surge chamber to flow longitudinally therein. To secure thelongitudinal ends of the flap 23 to the liner 45, the flap outer layer81 between the adhesive 93 and the distal end 79 of the flap 23 can besecured to the liner 45, such as with adhesive (not shown) or othersuitable fastening, generally at the longitudinal ends 80 of the flap tothereby close off the surge chamber 95 against flow longitudinallyoutward therethrough.

[0071] The flap outer layer 81 can be constructed of a spunbondpolypropylene non-woven web and the flap inner layer 67 can beconstructed of a polyethylene film to severely retard the flow of liquidbody waste outward of the flap 23. However, it is contemplated that theflap inner layer 67 may be constructed other than of a film or otherliquid impermeable material. For example, the flap inner layer 67 mayinstead be constructed of one or more layers of a liquid permeablematerial, and the liquid permeable material may be treated to decreasethe permeability thereof. It is also contemplated that the flap outerlayer 81 can be constructed of other liquid permeable materials, such asa polyethylene or polypropylene film having apertures formed therein topermit liquid body waste to flow therethrough to the surge chamber 95.Since the bodyside liner 45 is liquid permeable, the surge chamber 95 isgenerally in fluid communication with the absorbent body 47 to permitliquid body waste received in the surge chamber to pass through theliner for absorption by the absorbent body. When a surge of liquid bodywaste flows laterally outward along the medial region 77 of the liner45, it flows outward against the portion of the flap outer layer 81defining the surge chamber 95 and passes through the flap outer layerinto the surge chamber 95. The flap inner layer 67 inhibits liquid bodywaste received in the surge chamber 95 against flowing laterally outwardbeyond the containment flap 23. As a result, liquid body wasteaccumulates within the surge chamber 95 during the liquid surge, and istemporarily retained therein until the liquid body waist can passthrough the medial region 77 of the liner 45 interposed between thesurge chamber and the absorbent body for absorption by the absorbentbody 47.

[0072] While the flap outer layer 81 is shown and described herein asbeing constructed separate from the liner 45, it is contemplated thatthe flap outer layer may be secured to liner by being formed integrallytherewith, as long as the liner is interposed between the absorbent body47 and the surge chamber 95 formed by the flap outer layer and themedial surface 69 of the flap inner layer 67. For example, the liner 45may comprise at least two sheets (not shown) of material, with theliquid impermeable flap inner layer 67 being disposed between the twosheets and secured to a bottom sheet to form the base of the flap 23 andto the top sheet to form the distal end of the flap. While not shown inthe drawings, the flap inner layer 67 and/or the flap outer layer 81 mayalso extend transversely outward over the side panels 31, 38 of thetraining pants 21, and to the respective side edges 32 of the centralabsorbent assembly 25 of the pants, without departing from the scope ofthis invention.

[0073]FIG. 5 illustrates training pants 121 incorporating a secondembodiment of containment flaps 123. The containment flaps 123 aresubstantially similar to those shown in the embodiment of FIGS. 1-4,including a flap inner layer 167 having medial and lateral surfaces 169,171, and an outer layer 181. The flap outer layer 181 extends in opposedrelation with the medial surface 169 of the flap inner layer 167 and issecured thereto, such as by a suitable adhesive 191, to define a seam192 between the flap outer layer and the medial surface of the flapinner layer generally at the distal end 179 of the flap 123. However, aswith the first embodiment, the flap outer layer 181 need not be securedto the medial surface 169 of the flap inner layer 167 at the distal end179 of the flap 123, so that the adhesive 191 and seam 192 may beomitted.

[0074] Instead of the flap outer layer 81 being secured to the liner 45in laterally spaced relation with the base 74 of the flap 23 as in thefirst embodiment, the flap outer layer 181 of this second embodiment issecured to the liner 145 generally at the base 174 of the flap 123. Moreparticularly, the flap outer layer 181 is tucked between the liner 145and the medial surface 169 of the flap inner layer 167 at the base 174of the flap 123 and is secured to the liner and the flap inner layer,such as by being bonded thereto by respective suitable adhesives 193,197 to broadly define a second seam 199 of the flap outer layer and themedial surface of the flap inner layer. Alternatively, adhesive 197securing the flap outer layer 181 to the medial surface of the flapinner layer 167 may be omitted without departing from the scope of thisinvention.

[0075] The flap outer layer 181 is otherwise free from fixed engagementwith the medial surface 169 of the flap inner layer 167, and inparticular between the seam 192 and the seam 199. The width of theportion of the flap outer layer 181 extending between the seams 192, 199is substantially greater than the width of the flap inner layer, asshown in FIG. 5, or at least about equal thereto, so that this portionof the flap outer layer hangs generally loosely down along the medialsurface 169 of the flap inner layer 167 between the seams 192, 199 todefine a surge chamber 195 between this portion of the flap outer layerand the medial surface of the flap inner layer for receiving liquid bodywaste.

[0076] As in the first embodiment, the medial region 177 of the liner145 is interposed between the surge chamber 195 and the absorbent body47 of the training pants 121 of this second embodiment. As a result,when a surge of liquid body waste is received in the surge chamber 195,the liquid waste is temporarily retained therein until the liquid canflow back through the flap outer layer and through the medial region 177of the liner 145 interposed between the surge chamber and the absorbentbody 47 for absorption by the absorbent body.

[0077] It is contemplated that the flap outer layer 181 may be securedto the medial surface 169 of the flap inner layer 167 other than at thedistal end 179 of the flap 123 so that the seam 192 is spaced from thedistal end of the flap, and/or the flap outer layer may be furthersecured to the medial surface of the flap inner layer other than at thebase 174 of the flap so that the seam 199 is spaced from the base, aslong as the portions of the flap outer layer and flap inner layerextending between the seams 192, 199 are sized relative to each other sothat the flap outer layer and flap inner layer define the surge chamber195 therebetween.

[0078]FIG. 6 illustrates a pair of training pants 221 incorporatingcontainment flaps 223 of a third embodiment of the present invention.The containment flaps 223 of this embodiment are substantially similarto those shown in the embodiment of FIGS. 1-4, including a flap innerlayer 267 having medial and lateral surfaces 269, 271, and an outerlayer 281. The flap outer layer 281 extends in opposed relation with themedial surface 269 of the flap inner layer 267 and is secured thereto,such as by a suitable adhesive 291, to define a seam 292 between theflap outer layer and the medial surface of the flap inner layergenerally at the distal end 279 of the flap 223. The flap outer layer281 is secured to the medial region 277 of the liner 245, such as bybeing bonded thereto by suitable adhesive 293, in laterally spacedrelation with the base 274 of the flap 223 to form the surge chamber 295therebetween. In the embodiment of FIG. 6, a flow control member,generally indicated at 301, is disposed within the surge chamber 295 tocontrol the flow of liquid from the surge chamber through the liner 245into the absorbent body 47. In a particularly suitable embodiment, theflow control member 301 is a surge member adapted to quickly take in astream or gush of liquid (e.g., upon urination) and releasing the liquidslowly out of the surge chamber 295 through the liner 245 to theabsorbent body 47.

[0079] The surge material has suitable characteristics, such as asuitable basis weight, permeability, porosity, surface area per voidvolume (SA/VV), compression resiliency and saturation capacity. Furthercharacteristics can include a bonding matrix which will help stabilizethe pore size structure, and hydrophilicity. The bond-matrix and theblend of fiber deniers can advantageously provide for and substantiallymaintain a desired pore size structure.

[0080] For example, the surge member suitably has a basis weight in therange of about 20 gsm to about 120 gsm and a density in the range ofabout 0.008-0.025 grams per cubic centimeter.

[0081] The void volume of the fibrous nonwoven web is a measure of howmuch air space is present in the structure. The void volume is measuredat 689 dynes per square centimeter (0.01 pounds per square inch), andwill range from about 80 to about 117 cubic centimeters per gram ofsurge member with the target range being from about 80 to about 100cubic centimeters per gram of surge member. Void volume is the surgemembers's specific volume minus the fiber's (from which the surge memberis constructed) specific volume. For the purposes of the presentinvention, the specific volume is measured by a compression test at 0.01psi (with an INSTRON or SINTECH testing apparatus). For the surgemembers described herein, the void volume may approximately equal thespecific volume since the fiber specific volume is much less than thesurge member specific volume.

[0082] The permeability of the surge member indicates the ability of thesurge member to conduct a liquid therethrough. When a liquid initiallyenters a surge member, liquid movement is dominated by forced flow fromthe momentum of the fluid. Capillarity may not be significant in thisflow regime as it may not have enough time to control the liquid path,thus, liquid flow through the surge member will be controlled by thepermeability of the structure on the initial insult. A high permeabilityvalue indicates that it is relatively easy for a liquid to flow throughthe structure. Permeability for the surge member according to thepresent invention will range between about 7.8×10⁻⁵ to about 1.5×10⁻⁴square centimeters (8,000 to 15,000 darcy). Outside this range othermaterials have been found not to work as well. Permeability for surgemembers has been found to be related to the web's void volume, porosityand fiber surface area per void volume (SA/VV).

[0083] The porosity of the surge member is the ratio of the amount ofvoid space to the total volume of the surge member. The porosity of thesurge member, as measured at a pressure of 689 dynes per squarecentimeter (0.01 pounds per square inch), suitably ranges from about98.6% to about 99.4%. Porosity is one minus the ratio of the surgemember density. The density is measured by a compression test at 689dynes per square centimeter (0.01 psi) load.

[0084] The surface area per void volume, with the void volume beingmeasured at 689 dynes per square meter (0.01 pounds per square inch)pressure, suitably ranges from about 10 to about 25 square centimetersper cubic centimeter. Permeability is the result of fluid having totravel over and around fiber surfaces when under forced flow in order tooccupy the void spaces within the surge member. Surface area per voidvolume (SA/VV) indicates how closely together those fiber surfaces arelocated to each other. A high SA/VV value indicates that there is alarge amount of surface area which is placed closely together. Increasesin SA/VV can be achieved by using smaller fibers which increase thesurface area per unit weight of surge member, or by making the surgemember more dense which decreases the void volume per unit weight. WhenSA/VV is increased, permeability decreases since fluid is forced totravel over and around more surfaces to get through the structure. Ifthe SA/VV becomes too high, then the permeability will be too low toallow easy fluid entry into and flow through the surge member. Thus, theSA/VV of the surge member is suitably below 25 square centimeters percubic centimeter in order for the permeability to be above about 8,000darcy.

[0085] To ensure rapid intake of liquid, the surge member should havehydrophilic tendencies. At least a portion of the fibers should have acontact angle less than 90 degrees. As a result, the fibrous surgemember will have sufficient hydrophilic tendencies when the surge memberhas a saturation capacity greater than 55 grams of 0.9% saline solutionper gram of surge member. The surge member may also have a suitableresiliency in both the wet and dry states. For example, the surge membermay suitably have compression resilience values in both the wet and drystates of at least about 60%.

[0086] In one particular embodiment, the surge member may suitablycomprise a bonded, uniformly mixed, single layer structure having abasis weight of at least about 20 grams per square meter, a void volumebetween about 40 and 60 cubic centimeters per gram of material at apressure of 689 dynes per square meter (0.01 psi), a permeability ofabout 5,000 to about 8,000 darcy, a porosity of about 97.2% to about98.8% and a surface area per void volume of about 24 to about 49 squarecentimeters per cubic centimeter. Fibers from which the surge member maybe thermoplastic, and may be heat bonded to one another. In addition,the surge member of this embodiment can have a density within a range ofabout 0.017-0.025 grams per cubic centimeter, as determined at apressure of 689 dynes per square meter (0.01 psi).

[0087] For example, one suitable surge member includes a substantiallyhomogeneous single-layer fibrous nonwoven web having a basis weight ofabout 48.8 gsm created by using about 40 percent by weight HoechstCelanese type 295 6.0-denier polyester fibers and 60 percent by weightBASF 3.0-denier polyethylene sheath/polyester core bicomponent fibers.The homogeneous blend of fibers is bonded together using hot air passedthrough the surge member at a temperature of 135 degrees Celcius forapproximately 4 seconds. The resultant surge member has a void volume ofabout 52 cubic centimeters per gram of surge member, a SA/VV value ofabout 29.9 square centimeters per cubic centimeter, a porosity of about98.5%, a permeability of about 6,925 darcy, a saturation capacity ofabout 44 gm/gm, a wet compression resilience of about 81%, and a drycompression resilience of about 86%.

[0088] In other embodiments, the surge member can be made from orinclude a plurality of fibers bonded to one another to form a loftynonwoven web having a basis weight of at least 20 grams per square meter(gsm). In more refined embodiments the basis weight can range from about40 to about 68 grams per square meter. The surge member can be madeentirely from bicomponent fibers which are typically crimped and whichwill generally have a fiber denier equal to or greater than 2 denier.Alternatively, the surge member can be made from a combination of fiberssuch as bicomponent fibers and polyester fibers. In such embodiments,the surge member will usually include at least 50 percent by weight ofbicomponent fibers. The resultant surge member will have a void volumeof between about 80 and about 117 cubic centimeters per gram of surgemember at 689 dynes per square centimeter pressure, a permeability ofabout 8,000 to about 15,000 darcy, a porosity of about 98.6 to about99.4 percent, a surface area per void volume of about 10 to about 25square centimeters per cubic centimeter, a saturation capacity betweenabout 55 and about 80 grams of 0.9 percent saline solution per gram ofsurge member and a compression resilience in both the wet and dry stateof at least 60 percent. In addition, the surge member of theseembodiments can have a density within a range of about 0.008-0.013 gramsper cubic centimeter, as determined at a pressure of 689 dynes persquare meter (0.01 psi).

[0089] For example, in one such embodiment the surge member can includea single layer fibrous nonwoven web having a basis weight of about 49.8gsm created by using a uniform mixture of 40 percent by weight HoechstCelanese type 224, 6.0-denier polyester staple fibers and 60 percent byweight Chisso-type ES P, 3.0-denier by 38 millimeter polypropylenesheath/ polypropylene core bicomponent fiber. The surge member wasbonded using hot air at a temperature of 135 degrees Celcius forapproximately 4 seconds. The resultant surge member has a void volume ofabout 84 cubic centimeters per gram of surge member, a SA/VV value ofabout 20 square centimeters per cubic centimeter, a porosity of about98.9%, a permeability of about 9,256 darcy, a saturation capacity ofabout 59 gm/gm, a wet compression resilience of about 76%, and a drycompression resilience of about 76%.

[0090] As another example, the surge member can comprise a substantiallyhomogeneous single-layer fibrous nonwoven web having a basis weight of51.9 gsm and created by using 20 percent by weight Hoechst Celanese type295, 6.0-denier polyester fibers; 20 percent by weight Hoechst Celanesetype 183, 1.5 denier polyester fibers and 60 percent by weight BASF3.0-denier polyethylene sheath/polyester core bicomponent fibers. Thehomogeneous blend of fibers is bonded together using hot air at atemperature of 135 degrees Celcius for approximately 4 seconds. Theresultant surge member has a void volume of about 110 cubic centimetersper gram of surge member, a SA/VV value of about 16.2 square centimersper cubic centimeter, a porosity of about 99.3%, a permeability of about13,189 darcy, a saturation capacity of about 79 gm/gm, a wet compressionresilience of about 73%, and a dry compression resilience of about 70%.

[0091] In another embodiment, the surge member may be suitablyconstructed of a through-air-bonded-carded web of a homogeneous blend of60 percent 3 denier bicomponent fiber including a polyestercore/polyethylene sheath (commercially available from Kosa Corporationof Houston, Tex., U.S.A. under the designation T-256), and 40 percent 6denier type polyester fiber (commercially available from KosaCorporation under the designation T-295).

[0092] Additional details regarding suitable surge member constructionsand techniques for determining the above-described parameters are setforth in U.S. patent application Ser. No. 206,986 of C. Ellis and D.Bishop, entitled, FIBROUS NONWOVEN WEB SURGE LAYER FOR PERSONAL CAREABSORBENT ARTICLES AND THE LIKE, and filed Mar. 4, 1994 (Attorney docketNo. 11, 256); and in U.S. patent application Ser. No. 206,069 of C.Ellis and R. Everett, entitled, IMPROVED SURGE MANAGEMENT FIBROUSNONWOVEN WEB FOR PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE, andfiled Mar. 4, 1994 (Attorney docket No. 11,387). The disclosures ofthese documents are incorporated herein by reference to the extent thatthey are consistent herewith.

[0093] In other embodiments, the flow control member 301 may be otherthan a surge member and may contain absorbent material, such as thesuperabsorbent material described previously herein in connection withthe absorbent body 47 construction, whereby the flow control member iscapable of absorbing and retaining at least a portion of the liquidreceived in the surge chamber 295 during a surge or gush of liqud. Theflow control member 301 may also contain absorbent fibers, such as woodpulp fibers.

[0094] The flow control member 301 is suitably sized such that itoccupies a space within the surge chamber 295 (when the flow controlmember is dry) having a volume in the range of about 2 percent to about100 percent of the total volume of the surge chamber, and more suitablyin the range of about 5 percent to about 50 percent. It is contemplatedthat providing a relatively larger flow control member 301 within thesurge chamber 295 imparts increased shape resilience to the containmentflap 223. That is, the flow control member 301 facilitates thecontainment flap regaining its functional shape following compression(e.g., caused by normal usage such as sitting, walking, etc.) of thecontainment flap. Moreover, the flow control member 301 is shown in FIG.6 as being generally rectangular in cross-section and laying flat at thebase 274 of the flap 223 (e.g., the bottom of the surge chamber 295) insuperposed relationship with the liner 245. However, it is contemplatedthat the flow control member 301 may be other than rectangular incross-section, such as triangular in general correspondence with theshape of the surge chamber 295 as shown in the embodiment of FIG. 7,L-shaped, inverted V-shaped, square, ovate, circular, semi-circular,trapezoidal, or other suitable shape without departing from the scope ofthis invention. The flow control member 301 may also be tubular, e.g.,having a longitudinally extending channel (not shown) therein tofacilitate longitudinal transport of liquid within the flow controlmember (and hence the surge chamber 295).

[0095] It is also contemplated that the flow control member 301 may beoriented other than to lay flat at the base of the surge chamber 295,such as being oriented in generally superposed relationship with aportion or all of the flap outer layer 281, in generally superposedrelationship with a portion or all of the medial surface 269 of the flapinner layer 267, a combination thereof or a combination of one or bothof the above along with laying flat at the base of the surge chamber,such as is the case with the triangular shaped flow control memberillustrated in FIG. 7. For example, an L-shaped flow control member (notshown) may have a generally horizontal portion overlaying the liner 245within the surge chamber 295 at the base of the flap 223 and a verticalportion extending up along the flap outer layer 281 within the surgechamber.

[0096] The flow control member 301 is illustrated in FIG. 6 as beingsecured to the portion of the flap outer layer 281 that is secured tothe medial region 277 of the liner 245, such as by being bonded to theflap outer layer by suitable adhesive 305. It is contemplated that theflow control member 301 may also, or may instead, be secured directly tothe medial region 277 of the liner 245. Alternatively, or additionally,the flow control member 301 may be secured to the flap outer layer 281and/or to the medial surface 269 of the flap inner layer 267, or theflow control member may be otherwise unsecured within the surge chamber295. It is also contemplated that the flow control member 301 may extendonly partially along the height of the surge chamber 295, and/or theflow control member may comprise two or more discrete structuresarranged intermittently along the height of the surge chamber (e.g.,secured to the flap outer layer or the flap inner layer).

[0097] It is further understood that the liner 245 need not be disposedbetween the surge chamber 295 and the absorbent body 47, whereby theflow control member 301 within the surge chamber direcly overlays theportion of the absorbent body lying beneath the containment flap 223,and remain within the scope of this invention.

[0098]FIG. 8 illustrates training pants 321 incorporating containmentflaps 323 of a fourth embodiment of the present invention. Thecontainment flaps 323 are substantially similar to those shown in theembodiment of FIG. 5, in that they include a flap inner layer 367 havingmedial and lateral surfaces 369, 371, and an outer layer 381. The flapouter layer 381 extends in opposed relation with the medial surface 369of the flap inner layer 367 and is secured thereto, such as by asuitable adhesive 391, to define a seam 392 between the flap outer layerand the medial surface of the flap inner layer generally at the distalend 379 of the flap 323. The flap outer layer 381 of the containmentflap 323 of the embodiment of FIG. 8 is secured to the liner 345generally at the base 374 of the flap 323. More particularly, the flapouter layer 381 is tucked between the liner 345 and the medial surface369 of the flap inner layer 367 at the base 374 of the flap 323 and issecured to the liner and the flap inner layer, such as by being bondedthereto by respective suitable adhesives 393, 397 to broadly define asecond seam 399 of the flap outer layer and the medial surface of theflap inner layer.

[0099] As in the embodiment of FIG. 5, the width of the portion of theflap outer layer 381 extending between the seams 392, 399 issubstantially greater than the width of the flap inner layer 367, or atleast about equal thereto, so that this portion of the flap outer layerhangs generally loosely down along the medial surface 369 of the flapinner layer between the seams 392, 399 to define a surge chamber 395between this portion of the flap outer layer and the medial surface ofthe flap inner layer for receiving liquid body waste.

[0100] In this embodiment, a flow control member, generally indicated at401, is disposed within the surge chamber 395 to control the flow ofliquid from the surge chamber through the liner 345 into the absorbentbody 47. The flow control member 401 may be constructed substantiallythe same as the flow control member 301 shown in FIGS. 6 and 7 and/ordescribed previously herein. For example, the flow control member 401 inthe illustrated embodiment is generally rectangular in cross-section andlies generally flat at the base 374 of the flap 323 (e.g., at the bottomof the surge chamber 395). However, it is understood that the flowcontrol member 401 may be oriented to extend generally vertically withinthe surge chamber 395 and be generally ovate, or elliptical incross-section as shown in the embodiment of FIG. 9 to generallycorrespond to the shape of the surge chamber. It is also understood thatthe flow control member 401 may be generally other suitable shapes asdescribed previously that may or may not correspond generally to theshape of the surge chamber 395.

[0101] The flow control member 401 of the illustrated embodiments ofFIGS. 8 and 9 is secured to the portion of the flap outer layer 381 thatis secured to the liner 345, such as by being bonded to the flap outerlayer by suitable adhesive 405. However, it is understood that the flowcontrol member 401 may instead, or may additionally, be secured directlyto the liner 345. Alternatively, or additionally, the flow controlmember may be secured to the flap inner layer 367, or it may be freefrom securement within the surge chamber 395, without departing from thescope of this invention.

[0102] In view of the above, it will be seen that the several objects ofthe invention are achieved and other advantageous results attained. Whenintroducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

[0103] As various changes could be made in the above constructionswithout departing from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. An absorbent article for personal wear, saidabsorbent article comprising: an inner layer adapted for contiguousrelationship with the wearer, at least a portion of said inner layerbeing liquid permeable; an outer layer in opposed relationship with theinner layer; an absorbent body disposed between the inner layer and theouter layer of said article for absorbing liquid body waste; a pair ofcontainment flaps secured to the inner layer of said article in spacedrelation with each other, each flap having a base secured to the innerlayer of said article and a distal end, at least a portion of the distalend being movable relative to said base to a position in which saiddistal end is spaced from the inner layer of said article, saidcontainment flaps each comprising: a first layer extending from the baseof the flap to the distal end of said flap, said flap first layer havinga lateral surface and a medial surface; a liquid permeable second layerdisposed in generally opposed relationship with the medial surface ofthe flap first layer and being free from fixed engagement with at leasta portion of the medial surface of said flap first layer to define asurge chamber therebetween for receiving liquid body waste; and a surgemember disposed within the surge chamber for taking in liquid wastereceived in the surge chamber and releasing said liquid waste to theabsorbent body.
 2. The absorbent article set forth in claim 1 whereinthe liquid permeable portion of the inner layer is interposed betweenthe surge member and the absorbent body.
 3. The absorbent article setforth in claim 1 wherein the flap second layer has a width greater thana width of said portion of the medial surface of the flap first layer.4. The absorbent article set forth in claim 3 wherein said portion ofthe medial surface of the flap first layer extends substantially fromthe base of the flap to the distal end of the flap.
 5. The absorbentarticle set forth in claim 3 wherein the flap second layer is secured tothe medial surface of the flap first layer at a first seam therebetweengenerally at the distal end of the flap.
 6. The absorbent article setforth in claim 5 wherein the flap second layer is further secured to themedial surface of the flap first layer at a second seam spaced from saidfirst seam, said portion of the medial surface of the flap first layerextending between the first seam and the second seam.
 7. The absorbentarticle set forth in claim 6 wherein said second seam is locatedgenerally at the base of the flap.
 8. The absorbent article set forth inclaim 7 wherein the flap second layer is tucked between the medialsurface of the flap first layer and the inner layer of said articlegenerally at said second seam, said flap second layer being secured tothe inner layer of said article thereby securing the base of the flap tothe inner layer of said article.
 9. The absorbent article set forth inclaim 1 wherein the surge chamber has a volume, the surge memberoccupying a space within the surge chamber, said space having a volumein the range of about 2 to about 100 percent of the volume of the surgechamber.
 10. The absorbent article set forth in claim 9 wherein thespace occupied by the surge member has a volume in the range of about 5percent to about 50 percent of the volume of the surge chamber.
 11. Theabsorbent article set forth in claim 1 wherein the surge member has abasis weight in the range of about 20 gsm to about 120 gsm.
 12. Theabsorbent article set forth in claim 1 wherein the surge member has adensity in the range of about 0.008 to about 0.025 grams per cubiccentimeter.
 13. The absorbent article set forth in claim 1 wherein thesurge member is generally rectangular in cross-section.
 14. Theabsorbent article set forth in claim 1 wherein the surge member isgenerally triagular in cross-section.
 15. The absorbent article setforth in claim 1 wherein the surge member is generally ovate incross-section.
 16. An absorbent article for personal wear, saidabsorbent article comprising: an inner layer adapted for contiguousrelationship with the wearer, at least a portion of said inner layerbeing liquid permeable; an outer layer in opposed relationship with theinner layer of said article; an absorbent body disposed between theinner layer and the outer layer of said article for absorbing liquidbody waste; and a pair of containment flaps secured to the inner layerof said article in spaced relation with each other, each flap having abase secured to the inner layer of said article and a distal end, atleast a portion of the distal end being movable relative to said base toa position in which the flap is spaced from the inner layer of saidarticle, said containment flaps each comprising: a first layer extendingfrom the base of the flap to the distal end of said flap, said flapfirst layer having a lateral surface and a medial surface; a liquidpermeable second layer at least partially surrounding the lateral andmedial surfaces of the flap first layer, said flap second layer beingfree from fixed engagement with at least a portion of the medial surfaceof said flap first layer to define a surge chamber therebetween forreceiving liquid body waste; and a flow control member disposed in thesurge chamber for controlling the flow of liquid body waste received inthe surge chamber.
 17. The absorbent article set forth in claim 16wherein the flow control member comprises a surge member adapted to takein liquid body waste received in the surge chamber and release theliquid body waste to the absorbent body.
 18. The absorbent article setforth in claim 16 wherein the flow control member is adapted forabsorbing liquid body waste received in the surge chamber.
 19. Theabsorbent article set forth in claim 16 wherein the surge chamber has avolume, the flow control member occupying a space within the surgechamber, said space having a volume in the range of about 2 percent toabout 100 percent of the volume of the surge chamber.
 20. The absorbentarticle set forth in claim 19 wherein the space occupied by the flowcontrol member has a volume in the range of about 5 percent to about 50percent of the volume of the surge chamber.
 21. The absorbent articleset forth in claim 16 wherein the flow control member has a basis weightin the range of about 20 gsm to about 120 gsm.
 22. The absorbent articleset forth in claim 16 wherein the flow control member has a density inthe range of about 0.008 to about 0.025 grams per cubic centimeter. 23.The absorbent article set forth in claim 16 wherein the flow controlmember is generally rectangular in cross-section.
 24. The absorbentarticle set forth in claim 16 wherein the flow control member isgenerally triagular in cross-section.
 25. The absorbent article setforth in claim 16 wherein the flow control member is generally ovate incross-section.
 26. The absorbent article set forth in claim 16 whereinthe flap first layer is formed separate from the inner layer of saidarticle.
 27. The absorbent article set forth in claim 26 wherein theflap second layer is formed separate from the inner layer of saidarticle.
 28. The absorbent article set forth in claim 26 wherein theflap second layer inhibits contact of the flap first layer with thewearer's skin.
 29. The absorbent article set forth in claim 28 whereinthe flap second layer overlays substantially the entire lateral surfaceof the flap first layer.
 30. The absorbent article set forth in claim 26wherein the flap first layer is substantially liquid impermeable.
 31. Anabsorbent article for personal wear, said absorbent article comprising:an inner layer adapted for contiguous relationship with the wearer, atleast a portion of said inner layer being liquid permeable; an outerlayer in opposed relationship with the inner layer; an absorbent bodydisposed between the inner layer and the outer layer of said article forabsorbing liquid body waste; and a pair of containment flaps secured tothe inner layer of said article in spaced relation with each other, eachflap having a base secured to the inner layer of said article and adistal end, at least a portion of the distal end being movable relativeto said base to a position in which said distal end is spaced from theinner layer of said article, said containment flaps each comprising: afirst layer extending from the base of the flap to the distal end ofsaid flap, said flap first layer having a lateral surface and a medialsurface; a liquid permeable second layer in opposed relation with themedial surface of the flap first layer, said flap second layer beingfree from fixed engagement with at least a portion of the medial surfaceof said flap first layer to define a surge chamber therebetween forreceiving liquid body waste, said liquid permeable portion of the innerlayer of said article being interposed between the surge chamber and theabsorbent body of said article; and a flow control member disposedwithin the surge chamber for controlling the flow of liquid body wastereceived in the surge chamber.
 32. The absorbent article set forth inclaim 31 wherein the flow control member comprises a surge memberadapted to take in liquid body waste received in the surge chamber andrelease the liquid body waste to the absorbent body.
 33. The absorbentarticle set forth in claim 31 wherein the flow control member is adaptedfor absorbing liquid body waste received in the surge chamber.
 34. Theabsorbent article set forth in claim 31 wherein the surge chamber has avolume, the flow control member occupying a space within the surgechamber, said space having a volume in the range of about 2 percent toabout 100 percent of the volume of the surge chamber.
 35. The absorbentarticle set forth in claim 34 wherein the space occupied by the flowcontrol member has a volume in the range of about 5 percent to about 50percent of the volume of the surge chamber.
 36. The absorbent articleset forth in claim 31 wherein the flow control member has a basis weightin the range of about 20 gsm to about 120 gsm.
 37. The absorbent articleset forth in claim 31 wherein the flow control member has a density inthe range of about 0.008 to about 0.025 grams per cubic centimeter. 38.The absorbent article set forth in claim 31 wherein the flow controlmember is generally rectangular in cross-section.
 39. The absorbentarticle set forth in claim 31 wherein the flow control member isgenerally triagular in cross-section.
 40. The absorbent article setforth in claim 31 wherein the flow control member is generally ovate incross-section.
 41. An article for personal wear, said articlecomprising: a substrate adapted for contiguous relationship with thewearer of said article, and a pair of containment flaps secured to thesubstrate for contiguous relationship with the wearer of said article,the containment flaps being in spaced relation with each other, eachflap having a base secured to the substrate and a distal end, at least aportion of the distal end being movable relative to said base to aposition in which said distal end is spaced from the substrate of saidarticle, said containment flaps each comprising: a first layer extendingfrom the base of the flap to the distal end of said flap, said flapfirst layer having a lateral surface and a medial surface; a liquidpermeable second layer disposed in generally opposed relationship withthe medial surface of the flap first layer and being free from fixedengagement with at least a portion of the medial surface of said flapfirst layer to define a surge chamber therebetween for receiving liquidbody waste; and a surge member disposed within the surge chamber fortaking in liquid waste received in the surge chamber and subsequentlyreleasing said liquid waste for transfer out of said surge chamber.